U.S. patent application number 16/273646 was filed with the patent office on 2020-08-13 for flow meter systems and methods providing configurable functionality.
This patent application is currently assigned to Sensus Spectrum LLC. The applicant listed for this patent is Sensus Spectrum LLC. Invention is credited to Michael S. McCracken, Daniel W. Peace.
Application Number | 20200256711 16/273646 |
Document ID | / |
Family ID | 69771176 |
Filed Date | 2020-08-13 |
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United States Patent
Application |
20200256711 |
Kind Code |
A1 |
Peace; Daniel W. ; et
al. |
August 13, 2020 |
FLOW METER SYSTEMS AND METHODS PROVIDING CONFIGURABLE
FUNCTIONALITY
Abstract
A flow meter system for detecting the flow of a fluid between an
inlet and an outlet. A top plate is coupled to the inlet and the
outlet and a sensor is configured to detect the fluid flowing
therebetween. A main module is coupled between the inlet and the
outlet and has a main rotor configured to be rotated by the fluid
flowing through the main module. An output shaft is coupled to the
main rotor such that rotation of the main rotor causes rotation of
the output shaft. A first spacer is removably coupled between the
main module and the outlet. The first spacer is rotorless. The top
plate defines an opening that receives the output shaft. The first
spacer ensures alignment between the output shaft and the opening
defined in the top plate. The sensor senses rotation of the output
shaft to detect the flow of fluid.
Inventors: |
Peace; Daniel W.;
(Punxsutawney, PA) ; McCracken; Michael S.;
(Grampian, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sensus Spectrum LLC |
Raleigh |
NC |
US |
|
|
Assignee: |
Sensus Spectrum LLC
Raleigh
NC
|
Family ID: |
69771176 |
Appl. No.: |
16/273646 |
Filed: |
February 12, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01F 25/0007 20130101;
G01F 1/11 20130101; G01F 15/14 20130101; G01F 1/12 20130101 |
International
Class: |
G01F 1/12 20060101
G01F001/12; G01F 25/00 20060101 G01F025/00 |
Claims
1. A flow meter system for detecting the flow of a fluid between an
inlet and an outlet defining an internal space therebetween, a top
plate being configured to be coupled to the inlet and the outlet,
and a sensor being configured to detect the fluid flowing between
the inlet and the outlet, the flow meter system comprising: a main
module configured to be coupled between the inlet and the outlet
and to communicate the fluid therebetween, wherein the main module
includes a main rotor configured to be rotated by the fluid flowing
through the main module; an output shaft configured to be coupled
to the main rotor such that rotation of the main rotor causes
rotation of the output shaft; and a first spacer configured to be
removably coupled between the main module and the outlet and to
communicate fluid therebetween, wherein the first spacer is
rotorless; wherein the top plate defines an opening configured to
receive the output shaft from the main module, wherein the first
spacer is configured to ensure alignment between the output shaft
and the opening defined in the top plate, and wherein the sensor
senses rotation of the output shaft to detect the flow of
fluid.
2. The flow meter system according to claim 1, wherein the inlet
and the outlet each have an upstream end and an downstream end, the
internal space being defined between the downstream end of the
inlet and the upstream end of the outlet, wherein a total width is
defined between the upstream end of the inlet and the downstream
end of the outlet, and wherein the total width is fixed.
3. The flow meter system according to claim 2, wherein a first
width is defined between the downstream end of the inlet and the
output shaft, and wherein the first width is nominally 1.5
inches.
4. The flow meter system according to claim 2, further comprising a
center plate that is configured to be coupled between the main
module and the first spacer and to communicate fluid
therebetween.
5. The flow meter system according to claim 2, wherein the inlet
defines an inlet diameter, the outlet defines an outlet diameter,
and the first spacer defines a first spacer diameter, and wherein
the first spacer diameter is at least as great as at least one of
the inlet diameter and the outlet diameter.
6. The flow meter system according to claim 2, wherein a fluid flow
direction is defined between the inlet and the outlet of the flow
meter system, and wherein the output shaft is perpendicular to the
fluid flow direction.
7. The flow meter system according to claim 2, wherein the flow
meter system is upgradable to incorporate a secondary module in
place of the first spacer such that alignment between the output
shaft and the opening defined in the top plate is unaffected.
8. The flow meter system according to claim 2, further comprising a
second spacer configured to be coupled between the inlet and the
outlet and to communicate the fluid therebetween, wherein the
second spacer is rotorless.
9. The flow meter system according to claim 8, wherein the second
spacer is installable both between the inlet and the main module
and between the main module and the outlet.
10. The flow meter according to claim 2, wherein the top plate has
a short end and a long end that is opposite the short end, the
short end being closer than the long end to the opening, wherein
the top plate is configured to be coupled to the inlet and the
outlet both with the short end upstream of the long end and with
the short end downstream of the long end.
11. The flow meter according to claim 10, further comprising a
second spacer configured to be coupled between the inlet and the
outlet and to communicate the fluid therebetween, wherein the
second spacer is rotorless, wherein the opening is configured to be
aligned with the output shaft only when the short end of the top
plate is upstream of the long end.
12. A method of converting a flow meter system from a first type
having a first main module to a second type having a second main
module, each of the first main module and the second main module
being configured to communicate fluid between an inlet and an
outlet and also being configured to detect the flow of a fluid
therebetween, a top plate being coupled between the inlet and
outlet, the method comprising: uncoupling the top plate, wherein
when configured as the first type a short end of the top plate is
closer than a long end to the outlet; removing the first main
module from the flow meter system, wherein the first main module
includes a rotor configured to be rotated by the fluid flowing
through the first main module; coupling a first spacer and a second
spacer between the inlet and the outlet, wherein the first spacer
and the second spacer are each separate and rotorless; coupling the
second main module between the first spacer and the second spacer,
wherein the second main module includes a rotor configured to be
rotated by the fluid flowing through the second main module; and
rotating and coupling the top plate to the inlet and the outlet
such that the long end of the top plate is closer than the short
end to the outlet.
13. The method according to claim 12, wherein each of the first
main module and the second main module is configured to be coupled
to an output shaft, wherein rotation of the rotor causes rotation
of the output shaft, wherein the top plate defines an opening
configured to receive the output shaft.
14. The method according to claim 13, wherein coupling the first
spacer and the second spacer aligns the output shaft and the
opening defined in the top plate only when the top plate is coupled
such that the long end is closer than the short end to the
outlet.
15. A method of converting a flow meter system from a first type
having a first main module to a second type also having the first
main module, the first main module being configured to communicate
a fluid between an inlet and an outlet and having a rotor
configured to be rotated by the flow of the fluid and to
consequently rotate an output shaft, the method comprising:
removing a first top plate coupled to the inlet and the outlet;
removing the first main module from the flow meter system; removing
at least a first spacer coupled between the inlet and the outlet,
wherein the first spacer is rotorless; coupling the first main
module between the inlet and the output and closer to the inlet
than to the outlet; and one of: coupling the first top plate to the
inlet and the outlet, and coupling a second top plate that is
different than the first top plate to the inlet and the outlet.
16. The method according to claim 15, further comprising coupling a
secondary module between the inlet and the outlet, wherein the
secondary module has a secondary rotor.
17. The method according to claim 16, wherein the secondary module
is downstream of the first main module, and wherein the secondary
rotor of the secondary module has a different pitch than the rotor
of the first main module.
18. The method according to claim 16, wherein when configured as
the first type of flow meter system the first main module is
coupled between the first spacer and a second spacer, and wherein a
width of the secondary module is equal to the sum of a width of the
first spacer and a width of the second spacer.
19. The method according to claim 16, wherein the first spacer has
a width that is equal to a width of the secondary module.
20. The method according to claim 15, wherein an internal space is
defined between the inlet and the outlet, and wherein the internal
space is unchanged between the first type and the second type of
the flow meter system.
Description
FIELD
[0001] The present disclosure generally relates to flow meter
systems, and more particularly to flow meter systems providing
configurability of components to upgrade functionality.
BACKGROUND
[0002] The Background and Summary are provided to introduce a
foundation and selection of concepts that are further described
below in the Detailed Description. The Background and Summary are
not intended to identify key or essential features of the claimed
subject matter, nor are they intended to be used as an aid in
limiting the scope of the claimed subject matter.
[0003] The following U.S. Patents and Patent Applications are
incorporated herein by reference:
[0004] U.S. Pat. No. 5,877,430 discloses a turbine gas flow meter
that includes a meter body including an inlet portion having an
inlet body mounted therein. An exit end of the body inlet portion
is defined at an internal plenum of the meter body. A removable
turbine meter measuring module including a rotor assembly is
inserted into the plenum with an inlet end of the rotor assembly
and the exit end of the body inlet portion defining an interface
therebetween. A closed space is formed about the rotor assembly
within the plenum between an inner wall of the body and outer walls
of the rotor assembly. An axial gap between a surface of the rotor
assembly inlet end and a surface of the body inlet portion exit
end, and/or radial notches in either of the surfaces, provide fluid
pressure communication from the interface to the closed space. A
pressure tap extends through the body into the closed space for
measuring pressure within the closed space.
[0005] U.S. Pat. No. 6,453,757 discloses an ultrasonic gas meter
housing member configured to provide an associated
multi-configuration ultrasonic gas meter assembly. The housing
member is installable in an ultrasonic gas flow meter that includes
an internal flow measurement tube along which gas travels for flow
measurement, the tube having an inlet end and an outlet end. The
ultrasonic gas meter housing member includes a closed back portion
and a front portion spaced from the back portion to define a space
for receiving the internal flow measurement tube such that the tube
extends across the internal space of the housing member. At least
one wall portion extends between the back portion and the front
portion, the wall portion having a first opening and a second
opening therethrough for connection of the housing member to a gas
inlet pipe and a gas outlet pipe. The gas meter housing member is
symmetrical about a plane which divides the housing member into a
first portion and a second portion. The symmetrical configuration
enables the housing member to receive the flow measurement tube in
both a first orientation in which the first and second opening face
in a first direction and the inlet end of the flow measurement tube
is positioned in the first portion of the housing member and the
outlet end is positioned in the second portion, and a second
orientation in which the first and second opening face in a second
direction substantially perpendicular to the first direction and
the inlet end of the flow measurement tube is positioned in the
second portion of the gas meter housing member and the outlet end
is positioned in the first portion. The first and second
orientations are particularly useful in enabling the housing member
to be used both in gas meter installation sites where the gas pipes
extend downward, and in gas meter installation sites where the gas
pipes extend upward.
SUMMARY
[0006] One embodiment of the present disclosure generally relates
to a flow meter system for detecting the flow of a gas between an
inlet and an outlet defining an internal space therebetween. A top
plate is configured to be coupled to the inlet and the outlet, and
a sensor is configured to detect the fluid flowing between the
inlet and the outlet. The flow meter system includes a main module
configured to be coupled between the inlet and the outlet and to
communicate the gas therebetween. The main module includes a main
rotor configured to be rotated by the fluid flowing through the
main module. An output shaft is configured to be coupled to the
main rotor such that rotation of the main rotor causes rotation of
the output shaft. A first spacer is configured to be removably
coupled between the main module and the outlet and to communicate
gas therebetween. The first spacer is rotorless. The top plate
defines an opening configured to receive the output shaft from the
main module. The first spacer is configured to ensure alignment
between the output shaft and the opening defined in the top plate.
The sensor senses rotation of the output shaft to detect the flow
of gas.
[0007] Another embodiment generally relates to a method of
converting a flow meter system from a first type having a first
main module to a second type having a second main module, where
each of the first main module and the second main module is
configured to communicate gas between an inlet and an outlet, and
each is configured to detect the flow of a gas therebetween. The
top plate is coupled between the inlet and outlet. The method
includes uncoupling the top plate, where when configured as the
first type a short end of the top plate is closer than a long end
to the outlet. The method includes removing the first main module
from the flow meter system, where the first main module includes a
rotor configured to be rotated by the fluid flowing through the
first main module. The method includes coupling a first spacer and
a second spacer between the inlet and the outlet, where the first
spacer and the second spacer are each separate and rotorless. The
method includes coupling the second main module between the first
spacer and the second spacer, where the second main module includes
a rotor configured to be rotated by the fluid flowing through the
second main module. The method includes rotating and coupling the
top plate to the inlet and the outlet such that the long end of the
top plate is closer than the short end to the outlet.
[0008] Another embodiment generally relates to a method of
converting a flow meter system from a first type having a first
main module to a second type having a second main module, each of
the first main module and the second main module being configured
to communicate a gas between an inlet and an outlet and each having
a rotor configured to be rotated by the flow of the fluid and to
consequently rotate an output shaft. The method includes removing a
first top plate coupled to the inlet and the outlet, where the
first top plate has a short end and a long end and defines an
opening for receiving the output shaft, and where the short end is
closer than the long end to the outlet. The method includes
removing the first main module from the flow meter system and
removing a first spacer and a second spacer each coupled between
the inlet and the outlet. The first spacer and the second spacer
are each rotorless. The method includes coupling the second main
module between the inlet and the output, where the second main
module is different than the first main module. The method includes
coupling a second top plate to the inlet and the outlet, where the
second top plate has a short end and a long end and defines an
opening for receiving the output shaft, and where the second top
plate is coupled such that the output shaft of the second main
module aligns with the opening.
[0009] Various other features, objects and advantages of the
disclosure will be made apparent from the following description
taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The drawings illustrate the best mode presently contemplated
of carrying out the disclosure. The same numbers are used
throughout the drawings to reference like features and like
components. In the drawings:
[0011] FIGS. 1 and 2 are sectional side views of flow meter systems
presently known in the art;
[0012] FIG. 3 is a sectional side view of one embodiment of a flow
meter according to the present disclosure;
[0013] FIG. 4 is an exploded side view of a flow meter
substantially similar to that shown in FIG. 1 being upgraded or
reconfigured from the device of FIG. 3 according to the present
disclosure;
[0014] FIG. 5 depicts a side view of a flow meter similar to that
shown in FIG. 2;
[0015] FIG. 6 depicts a side view of one embodiment of a flow meter
after being upgraded or reconfigured from the embodiment of FIG. 5
according to the present disclosure;
[0016] FIGS. 7 and 8 are partial, exploded side views of the
devices shown in FIGS. 3 and 6, respectively;
[0017] FIG. 9 depicts an exploded isometric view of one embodiment
of a flow meter according to the present disclosure similar to that
depicted in FIGS. 6 & 8;
[0018] FIG. 10 is a front view of a spacer from FIG. 9;
[0019] FIG. 11 is a rear view of the main module from FIG. 9;
and
[0020] FIGS. 12 and 13 are front views of an exemplary center plate
and another spacer from FIG. 9, respectively.
DETAILED DISCLOSURE
[0021] This written description uses examples to disclose
embodiments of the present application, including the best mode,
and also to enable any person skilled in the art to practice or
make and use the same. The patentable scope of the invention is
defined by the claims and may include other examples that occur to
those skilled in the art. Such other examples are intended to be
within the scope of the claims if they have structural elements
that do not differ from the literal language of the claims, or if
they include equivalent structural elements with insubstantial
differences from the literal language of the claims.
[0022] Flow meters are devices commonly installed at residential,
commercial, or industrial buildings to measure the consumption of
fluid, such as natural gas provided by a utility. Existing flow
meters provided by Sensus Spectrum LLC include both single rotor
and dual rotor models, including the commercially available turbine
meter "MKII" and the automatically adjusting "AAT," respectively.
These flow meters are presently available in four, six, eight, and
twelve inch sizes and with pressure rated bodies and top plates of
175, 220, 270, 750, and 1500 PSIG operation and flange classes.
Different models are also available for differing flow capacities,
including a "standard" model with a 45 degree rotor blade angle and
a "high" capacity 30 degree rotor blade angle.
[0023] The single rotor MKII design originated in the 1970s,
whereas the dual rotor AAT later design was developed to fit into
existing MKII bodies, using new top plates and internal components.
The AAT models offer advanced features beyond those provided with
the MKII design. However, both models continue to be extensively
used in the field. As a result, the different pressure rating,
flange size, and flow capacity offerings available across these
product lines requires production and inventory for a large number
of distinct top plates, main rotors, module carriers, and bearing
brackets to continue to support both product lines and all
variations therein. The present inventors have further identified
that the lack of interchangeability of components in existing
systems, other than reusing a common body, results in increased
cost and complexity for a user to upgrade from an MKII model to an
AAT model to obtain this increased functionality.
[0024] Accordingly, the present inventors have developed the
presently disclosed systems and methods for reducing production and
inventory costs by providing interchangeability of components for
flow meter systems to provide different functionality.
Additionally, the presently disclosed systems and methods further
decrease the financial barrier for users wishing to upgrade in the
future. The present disclosure outlines a newly-designed single
rotor AT model "Advanced Turbo," which provides a new production
alternative to existing single rotor MKII models. The AT model
includes components of the AAT model and therefore most of the
features, except for automatic adjusting. Among other changes, a
new spacer of the AT takes the place of the secondary rotor module
of an AAT model. As will be discussed later, upgrade paths include
that from an existing MKII device to a new MKIII device as
presently disclosed, as well as paths from a new AT or from a new
MKIII to the full AAT capability. In certain embodiments, which are
discussed further below, the new single rotor MKIII model uses the
existing MKII top plate, in a reversed position, plus two new
spacers, as well as components of the AAT. This realizes some of
the features, except for automatic adjusting. This embodiment
enables the upgrading an AT model to full AAT capability by
replacing the spacer with a secondary rotor module. Similarly, the
presently disclosed embodiments enable upgrading a MKIII to full
AAT capability by replacing the MKII top plate with that of an AAT
model, with both spacers being replaced with a secondary rotor
module. Any of these future upgrade steps provide various
considerations for economical choices by the end user.
[0025] The presently disclosed systems and methods are applicable
to flow meter systems of all sizes, pressure ratings, and flow
capacities. Therefore, the present disclosure will generally refer
to sizing, pressure rating, and flow capacity generically.
Moreover, it should be recognized that the presently disclosed
systems and methods are also applicable to other sizes, pressure
ratings, and flow capacities not previously discussed or presently
offered. For example, this includes different pitches for one or
more rotors in the one or more modules contained within a given
flow meter system.
[0026] Similarly, the presently disclosed systems and methods are
generally disclosed as relating to a system in which an output
shaft is rotated by a rotor to be sensed by a sensor within the top
plate. In other words, a sensor detects the mechanical rotation of
an output shaft to detect the flow of fluid. However, the
particular sensors and mechanisms for detecting rotation of the
rotor (or rotors), or other techniques for detecting fluid flow,
are not limited by the present disclosure.
[0027] FIGS. 1 and 2 depict flow meter systems presently known in
the art, specifically an AAT model and an MKII model, respectively.
As shown, each flow meter system 10 is installable at the inlet 20
and outlet 30 between corresponding portions of a flow pipe 8. The
flow meter system 10 is configured to detect the flow of fluid
between the inlet 20 and the outlet 30 in the customary manner. The
inlet 20 and the outlet 30 are separated by a total width W1, which
in the present example is consistent across the flow meters
presently known in the art and those disclosed herein, which vary
depending upon body size and pressure rating. The inlet 20 has an
upstream end 22 and a downstream end 24 with an inlet diameter 26,
and the outlet 30 has an upstream end 32 and a downstream end 34
and an outlet diameter 36. An internal space W2 is defined between
the downstream end 24 of the inlet 20 and the upstream end 32 of
the outlet 30, which also remains unchanged between flow meters
presently known in the art and the systems and methods presently
disclosed, depending upon body size.
[0028] By way of example, the internal spaces W2 for both AAT and
MKII flow meter systems 10 of four, six, eight, and twelve
diameters are nominally 4.000, 5.002, 5.125, and 7.257 inches
respectively. In certain embodiments, retention lips 28 and 38
defined within the inlet 20 and outlet 30 ensure proper alignment
and orientation of components coupled thereto. Moreover, these
features prevent interference between installed components and
others within the inlet 20 and/or outlet 30, such as the nose cone
60 within the inlet 20 in existing AAT and MKII models.
[0029] In certain embodiments, the inlet diameter 26 of the inlet
20 is equal to the outlet diameter 36 of the outlet 30. Likewise,
certain embodiments are configured such that all components
installed between the inlet 20 and the outlet 30 have this same
diameter, and/or define openings such that the flow F of fluid is
minimally diverted or resisted therebetween.
[0030] A top plate 40, (such as 41A for MKII or 41B for AAT), is
configured to be coupled to the inlet 20 and the outlet 30 with an
incorporated sensor 50 that is configured to detect the fluid
flowing between the inlet 20 and the outlet 30. One of a type-A
main module 70A for a first type of flow meter system 10 (such as
is used in the MKII model), or a type-B main module 70B for a
second type of flow meter system 10 (such as is used in the AAT
model), is configured to be coupled between the inlet 20 and the
outlet 30 and to communicate the fluid therebetween. The type-A
main module 70A or type-B main module 70B includes a main rotor 72
that is rotated by the fluid flowing therethrough. Additional
information relating to the type-A main module 70A and type-B main
module 70B, and other flow meter systems of this nature, is also
provided in U.S. Pat. No. 5,877,430, which is incorporated by
reference herein. It should be recognized that while the present
disclosure principally refers to two types of main modules (type-A
and type-B), different modules for type-A and/or type-B are
anticipated, provided that type-A and type-B are distinguishable
from each other. It should be further recognized that references to
a "first" or "second" main module may refer to either the type-A
module or the type-B module and is generally used as an indicator
of the order in which the modules are installed in a given section
of pipe. The same references may also be made to spacers (discussed
below), whereby ordinal references will in most cases indicate the
order of installation rather than a fixed type of spacer.
[0031] An output shaft 48 is coupled to the main rotor 72, either
directly or indirectly, such that rotation of the main rotor 72
causes rotation of the output shaft 48. The output shaft extends
through an opening 78 in the respective module, type-A main module
70A or type-B main module 70B (see FIG. 11). The top plate 40
defines an opening 42 that is positioned and configured to receive
the output shaft 48 such that the sensor 50 can sense the rotation
of the output shaft 48 to detect the flow of fluid in the customary
manner.
[0032] Among the primary distinctions between the flow meter
systems of FIG. 1 and FIG. 2 is the presence of a secondary module
80 incorporating a second rotor 82 for the device shown in FIG. 1.
A center plate 90 is coupled between the type-B main module 70B and
the secondary module 80 to provide proper alignment and separation
therebetween. This same center plate 90 is configured to function
in the embodiments shown in FIGS. 1, 3-4, and 6-9. Generally, the
type-A main module 70A or type-B main module 70B, also referred to
as measuring modules, contain main rotor 72 which respond to the
flow and cause rotation of the output shaft 48 as previously
discussed such that the sensor 50 can detect the flow passing
between the inlet 20 and the outlet 30.
[0033] When present, a secondary module 80, also referred to as a
sensing module, increases the accuracy of the flow meter system 10
by providing automatic adjusting and self-checking features. In
some embodiments, the output of the sensing module is linked with
constant remote accuracy monitoring capabilities and in-line field
diagnostics. Specifically, the main rotor 72 has a pitch 74, and
the secondary rotor 82 has a pitch 84, which in the present case is
different than the pitch 74. This results in the respective main
rotor 72 and secondary rotor 82 rotating at different rates within
the same flow of fluid. The ratio of these different rates serves
as a means for checking the accuracy of the type-B main module 70B,
since the type-B main module 70B and secondary module 80 should
have a consistently, known relationship of ratio over a wide range
of rates of flow. The embodiment of FIG. 2 does not include a
secondary module 80, thus lacking at least this checking means for
monitoring the accuracy of a main rotor 72.
[0034] As shown in FIGS. 1-8 and 11, the type-A main module 70A and
type-B main module 70B have widths 71, diameters 73, and annular
exteriors 75. A center 76 supported by ribs 79 is coupled to the
annular exterior 75 define a plurality of exterior openings 77
therein (see FIG. 11). The exterior openings 77 permit the fluid to
flow from the inlet 20 to the outlet 30 through the type-A main
module 70A or type-B main module 70B, thereby rotating the main
rotor 72 positioned therein. Exterior openings in spacers, such as
exterior opening 126 in the second spacer 120 defined by the annual
exterior 125 (see FIGS. 6 and 10) align with these exterior
openings 77, which are discussed below. Similarly, the secondary
module 80, when present as in FIGS. 1 & 4, has a width 81, and
diameter 83. Similarly to the type-A main module 70A and type-B
main module 70B, the secondary module 80 has a center supported by
ribs coupled to the annular exterior to define a plurality of
external openings therein (not separately shown). These exterior
openings 87 permit flow of the fluid from the inlet 20 to the
outlet 30 through the secondary module 80, thereby rotating the
secondary rotor 82.
[0035] The devices shown in FIGS. 1 and 2 are further distinguished
in the specific type of top plate 40 used: a first top plate 41A or
a second top plate 41B. Each top plate 40 can be described as
having a short end 43 and a long end 45 that is opposite the short
end 43, whereby the short end 43 is closer than the long end 45 to
the opening 42 defined within the top plate 40. Further, an
alignment width W3 is defined between the downstream end 24 of the
inlet 20 and a shaft axis A defined within the center of the
opening 42. Likewise, width W4 is defined between the shaft axis A
and the upstream end 32 of the outlet 30 (see FIGS. 5 and 6). In
this manner, the alignment width W3 is smaller for the flow meter
system 10 shown in FIG. 1 than that shown in FIG. 2. This is the
case because the flow meter system 10 of FIG. 2 has a first top
plate 41A with its short end 43 downstream of its long end 45, in
contrast to that of FIG. 1.
[0036] FIG. 3 shows one embodiment of a flow meter system 10
according to the present disclosure that provides for easy
configuration or upgradability of components and corresponding
functions. In particular, the flow meter system 10 of FIG. 3 is a
single rotor system having a type-B main module 70B, but in place
of a secondary module 80 has a first spacer 110 that is rotorless
and has a width 111. The first spacer has an annual exterior 115
(see FIG. 9). As is also shown in FIG. 13, the first spacer 110 has
a diameter 113, and an annular exterior 115. A center hub opening
114 is defined within the solid hub 118 is coupled to the annular
exterior 115 by ribs 112, wherein the solid hub 118 has a diameter
119 and the center hub opening 114 has a diameter 117. As with the
type-B main module 70B, a plurality of external openings 116 is
defined within the first spacer 110 to permit fluid to flow
therethrough. By incorporating the first spacer 110, the flow meter
system 10 can be upgraded to include a secondary module 80 while
still reusing the same second top plate 41B, saving time and
expense for upgrading.
[0037] As shown in the exploded view of FIG. 4, the flow meter
system 10 from FIG. 3 may be upgraded (in this case from a newly
disclosed "AT" model to an AAT model) by removing the top plate 40
and the first spacer 110, and instead coupling a secondary module
80 and the existing type-B main module 70B with the center plate 90
therebetween. As is also shown in FIG. 12, a plurality of exterior
openings 97 are defined by the center plate 90 between an annual
exterior 95 and a center 94 coupled thereto by ribs 92. These
exterior openings 97 allow flow through the center plate 90. The
flow meter system 10 is configured such that the width 111 of the
first spacer 110 allows this replacement with the secondary module
80. In certain embodiments, the width 111 of the first spacer 110
is the same as the width 81 of the secondary module 80. However, in
other embodiments it is the sum total width of respective installed
components is equal for the system shown in FIG. 3 and the upgraded
system shown in FIG. 4.
[0038] By way of example, AAT models at the four, six, eight, and
twelve inch diameter sizes have nominal widths 71 of 2.301, 2.839,
2.838, and 4.020 with respective secondary module 80 widths 81 of
1.493, 1.828, 1.954, and 2.868 and respective center plate 90
widths 91 of 0.184, 0.311, 0.311, and 0.347. Additional widths of
seals and ball plungers include maximums of 0.007, 0.007, 0.007,
and 0.008, respectively. Similarly, present MKII models have type-A
main modules 70A for the four, six, eight, and twelve inch
diameters having nominal widths 71 of 3.985, 4.985, 5.110, and
7.243 inches. In this manner, the respective components, along with
the tolerances of each, fit within the internal spaces W2
previously provided.
[0039] Similarly, FIGS. 5 and 6 depict the ability to upgrade from
a present flow meter system 10, such as that shown in FIG. 2, (see
FIG. 5) to one embodiment of a new flow meter system 10 presently
disclosed (also referred to as an "MKIII" model, see FIG. 6). In
the present case, the type-A main module 70A is removed from the
flow meter system 10 shown in FIG. 5 after removing the top plate
40, which in the present case is a first top plate 41A. In the
present embodiment, the type-A main module 70A is of the same type
used in the embodiment shown in FIG. 2, such as the MKII device
presently deployed in the field.
[0040] As can be seen in FIG. 6, the type-A main module 70A is
replaced with a type-B main module 70B, which resembles the type-B
main module 70B of the embodiment shown in FIG. 1, such as used by
the AAT models presently deployed in the field. This upgrade alone
from a type-A main module 70A to a type-B main module 70B provides
improved functionality between the flow meter system 10 shown in
FIG. 5 and that shown in FIG. 6, keeping the existing field top
plate 41A. However, this configuration also disturbs the alignment
between the top plate 40 and the output shaft 48 from that shown in
FIG. 5. Accordingly, the present inventors have developed the
presently disclosed flow meter system 10 to easily and cost
effectively restore such alignment. Specifically, by incorporating
the first spacer 110 downstream of the type-B main module 70B,
along with the addition of a second spacer 120 upstream of the
type-B main module 70B, the top plate 40 shown in FIG. 5 (depicted
in that configuration as first top plate 41A) can be rotated 180
degrees (now designated as reversed, first top plate 41AR) such
that the output shaft 48 is once again in alignment with the
opening 42 defined in the top plate 40. In other words, the same
top plate 40 may be used between the embodiments of FIGS. 5 and 6,
requiring only the addition of the first spacer 110 and second
spacer 120 to upgrade from type-A main module 70A to type-B main
module 70B.
[0041] In the embodiment shown, the first spacer 110 and second
spacer 120 are rotorless. An exemplary second spacer 120 is also
shown in FIG. 10, which shows a center opening 124 defined within a
structure coupled by ribs 122 to the annual exterior 125. In this
manner, an MKIII model (FIG. 6) may be upgraded to incorporate the
improved features of the AT model (FIG. 3) while allowing the use
of the existing top plate 41A.
[0042] It will be recognized that the first spacer 110 of certain
configurations (FIG. 3) necessarily have a greater width 111 than
the first spacer 110 in other configurations (FIG. 6). However, the
internal space W2 and the width 71 of the type-B main module 70B
are consistent in each of these configurations. Therefore, the
present inventors have identified that further savings and/or
reduction of inventory can be achieved by combining the first
spacer 110 and the second spacer 120 of the configuration of FIG. 6
to together form the first spacer 110 in the configuration of FIG.
3. In this manner, only two widths of spacers are required across
these various embodiments, rather than dedicated spacers for all
three widths.
[0043] It should be recognized that the sensor 50 may, in certain
embodiments, also have to be replaced to realize the full
functionality of the upgrade from the configuration shown in FIG. 5
to that shown in FIG. 6.
[0044] FIGS. 7 and 8 further depict the newly developed flow meter
systems 10 previously discussed (here, AT and MKIII models,
respectively), each being upgradable by incorporation of
appropriately-sized and positioned spacers. In particular, the
embodiment shown in FIG. 7 incorporates a first spacer 110, whereas
the embodiment shown in FIG. 8 includes both a first spacer 110 and
a second spacer 120. It should be recognized that while both
embodiments discuss the use of a "first spacer," the first spacer
110 of the embodiment shown in FIG. 7 is, in certain embodiments,
not the same as the first spacer 110 shown in FIG. 8. Additional
views of the MKIII device are shown in FIGS. 9-13. The elements
shown in FIGS. 11-12 are also used for AAT and AT models as
well.
[0045] The embodiments shown in FIGS. 7 and 8 further disclose the
incorporation of ball plungers 142, which ensure proper seating and
alignment between components. The embodiment of FIG. 7 (the AT
model), ball plungers 142 generate a spring force against the
downstream end 24 of the inlet 20 (see FIG. 1) to properly position
and energize the module-to-body seal ring 140. This is necessary to
allow them to directly act against the inlet 20, and also to
provide improved module sealing and proper alignment against
surface 32 of the outlet 30. The same configuration is also used
for the AAT model (FIG. 1). In the embodiment shown, the MKII model
does not have provisions for ball plungers or the seal ring (FIG.
2).
[0046] These alignment features, along with fasteners 12 and
corresponding openings 14 for receiving the fasteners 12
therethrough, provide alignment and/or coupling between the
components discussed herein. In certain embodiments, such as that
shown in FIG. 9 (with the rotor 72 removed for clarity), the
openings 14 are defined within components for receiving fasteners
12, which may be threaded or through holes. The openings 14 are
also shown to be counter-bored to accommodate for the head of the
fasteners 12 to provide for flush coupling between elements. The
embodiment shown further incorporates or defines holes 143 for
receiving the ball plungers 142 previously discussed (see FIG. 10
and FIG. 7, for example). As with the openings 14, the holes 143
may be counter-bored, or be provided with a corresponding recess 16
to accommodate the head flange of a ball plunger 142, preventing it
from interfering with flush installation between coupled
components.
[0047] In addition to the flow meter systems 10 previously
disclosed, the present disclosure further relates to a method of
converting a flow meter system 10 from a first type having a type-A
main module 70A to a second type having a type-B main module 70B.
As previously discussed, certain embodiments also incorporate a
secondary module 80. Each of the type-A main module 70A and type-B
main module 70B (and where applicable, the secondary module 80) are
configured to communicate fluid between an inlet 20 and an outlet
30, and also configured to detect the flow F of fluid therebetween,
as previously discussed.
[0048] A top plate 40 is configured to be coupled between the inlet
20 and the outlet 30 in the customary manner. The method includes
uncoupling the top plate 40, which when the flow meter system 10 is
configured the first type has a short end 43 that is closer than a
long end 45 to the outlet 30. The short end 43 is defined to be
closer than the long end 45 to an opening 42 defined in the top
plate 40, which is configured to receive an output shaft 48 as
previously described. Next, the type-A main module 70A is removed
from the flow meter system 10, wherein the type-A main module 70A
includes a rotor configured to be rotated by the fluid flowing
through the type-A main module 70A. The method includes coupling a
first spacer 110 and a second spacer 120 (having a width 121)
between the inlet 20 and the outlet 30, whereby the first spacer
110 and the second spacer 120 are separate and rotorless. The
method further includes coupling the type-B main module 70B between
the first spacer 110 and the second spacer 120, whereby the type-B
main module 70B includes a rotor configured to be rotated by the
fluid flowing through the type-B main module 70B. In certain
embodiments, the center plate 90 is coupled between the type-B main
module 70B and the first spacer 110. Finally, the method includes
rotating and coupling the top plate 40 to the inlet 20 and outlet
30 such that the long end 45 of the top plate 40 is closer than the
short end 43 to the outlet 30. In particular, this process may be
used to convert an MKII device to a new MKIII device as presently
disclosed, for example.
[0049] Similarly, the present disclosure includes a method of
converting a flow meter system 10 from a first type having a type-B
main module 70B to a second type also having a type-B main module
70B, in certain embodiments also including a secondary module 80.
The type-B main module 70B, as well as the secondary module 80 when
present, is configured to communicate fluid between an inlet 20 and
an outlet 30. The type-B main module 70B has a rotor configured to
be rotated by the flow of fluid and to consequently rotate an
output shaft 48. The secondary module 80 also has a rotor and, in
certain embodiments, provides error checking in the manner
previously described.
[0050] The method includes removing a reversed first top plate 41AR
coupled to the inlet 20 and the outlet 30, whereby the reversed
first top plate 41AR has a short end 43 and a long end 45 and
defines an opening 42 for receiving the output shaft 48 such that
the short end 43 is closer than the long end 45 to the opening 42.
The method includes removing the type-B main module 70B from the
flow meter system 10, and removing a first spacer 110 and a second
spacer 120, as shown in FIG. 6, that are each coupled between the
inlet 20 and the outlet 30. In the present embodiment, both the
first spacer and the second spacer are rotorless. The method
includes re-coupling the type-B main module 70B between the inlet
20 and the outlet 30 with either a secondary module 80 or a first
spacer 110 as shown in FIG. 3. Finally, the method includes
coupling a second top plate 41B to the inlet 20 and the outlet 30,
whereby the second top plate 41B has a short end 43 and a long end
45 and defines an opening 42 for receiving the output shaft 48 such
that the second top plate 41B is coupled in a manner that the
output shaft 48 of the type-B main module 70B aligns with the
opening 42. This method may be used to convert an MKIII system as
presently described to a full AAT system known in the art, or an AT
system such as that shown in FIG. 3, for example.
[0051] It should be recognized that the presently disclosed systems
and methods may also be used to develop further configurations not
expressly discussed above. These may include different flow meter
systems 10 that are convertible to have the same setup or features
as presently known systems, or to further new flow meter systems 10
Likewise these may include the conversion of different presently
known flow meter systems 10 to other presently known systems, or to
other new flow meter systems 10 and/or functionality.
[0052] In the above description, certain terms have been used for
brevity, clarity, and understanding. No unnecessary limitations are
to be inferred therefrom beyond the requirement of the prior art
because such terms are used for descriptive purposes and are
intended to be broadly construed. The different assemblies
described herein may be used alone or in combination with other
devices. It is to be expected that various equivalents,
alternatives and modifications are possible within the scope of any
appended claims.
* * * * *